Dry cell battery unit



Jan. 12, 1943. c. P. DEIBEL DRY CELL BATTERY UNIT Filed Aug. 15, 1941 2 Sheets-Sheet l FIGI.

FIG-7.

INVENTOR P. DEIBEL Wad.

ATTORNEYS FIGZ.

BY f 4y PLIOFILM c. P. DEIBEL 2,307,765

DRY CELL BATTER-Y mm- Filed Aug. 15, 1941 2 Sheets-Sheet 2 ATTORNEYS.

tery is reducedto-a minimum.

Patented Jan. 12, 1943 UNITED STATES PATENT OFFICE I 2,307,765 c a c DRY can; BATTERY UNIT Cyril r. DeibeLLakewood, Ohio Application August 15, 1941, Serial No. 407,015

'8 Claims. (Cl. 136-111) This invention relates to a dry cell battery unit which is made up of a plurality of separate dry cellssealed within an outer casing in such a manner that the likelihood of leakage of electrolyte is reduced to a minimum, and which is particularly well adapted for use with hearing aids, portable radios or the like where space is at a premium and where a leak-proof battery is desirable.

This application is a continuation in part of my application Serial No. 399,196, filed June 21, 1941 for- Dry cell battery unit and in which is disclosed the method and apparatus for producinug a dry cell battery unit and which application contains claims directed to the dry cell bat- ,tery unit.

efliciency of the battery unit, which weaknesses are overcome by the improvement herein disclosed.

In the invention herein disclosed each mass electrode so as to insure intimate electrical cone tact between adjacent cells.

A further object of the invention is to provide a dry cell battery unit which contains the maximum quantity of active materials and a minimum quantity of inactive materials and which is substantially identical possessed two weakof mix is enclosed within an' annular -or circular ring formed of fish paper or other suitable material which serves to preventdehydration of the I mix or a squeezing out of the electrolyte. This also prevents the electrolyte from being forced out of the mix between the insulating cover carbon electrode which when contacting an adjacent zinc electrode forms an electro-couple.

The cell herein disclosed possesses a further feature or means which insures intimate contact between each carbon electrode and the next adjacent zinc electrode. Each carbon button is recessed at the top and contains therein a springlike member which is preferably formed of phosphor-bronze and which serves to provide good electrical contact between the carbon button and the next adjacent zinc electrode.

One of the objects of the invention is to provide a' dry cell-battery unit in which the likelihood of dehydration of the mix or a squeezing out of the electroLvte in the processor forming the bat- A further object oi! the invention is to provide a dry cell battery unit of the character described and which is provided with a spring-like electritween each carbon button and the adjacent zinc and has a high potential and a relatively high capacity.

Another object of the invention is to provide a dry cell battery unit comprising ametal casing in which are arranged a plurality of dry cells which are held in electrical contact with each other under pressure, each cell being enclosed within a layer of insulating material and individually sealed in liquid-tight relation with each other.

A further object of the invention is to provide a dry cell battery unit having the above described distinctive characteristics and features and iii-which the number of soldered connections are reduced to a minimum and which will give a maximum of service hours and have a relatively long shelf life as well as an active life.

A still further object of the inventionis to provide a dry cell battery unit of the character described which may be made in any particular size or. shape and which may consist of any desirednumber of cells to give the desired voltage and capacity.

.A further object of the invention is to provide a dry cell battery unit which comprises a metal casing containing a plurality of, wafer-like-dry cells arranged therein in stacked relation and connected in series, each cell comprising a zinc electrode, a mass of mix containing an electrolyte and a carbon electrode, the upper surface of the carbon electrode of each cell being embedded in the adjacent mass of mix and having an exposed surface having electrical contact with the zinc electrode of the next adjacent cell, each cell-being also encased within'a thin layer of insulator the like, in

mg material, such as Pliofilm liquid-tight relation therewith and sealed to the carbon electrode of the next adjacent cell, the zinc electrode of the lowermost cell having elec-: trical contact with the metal casing and the carbon electrode of the uppermost cell having sealed engagement with the next adjacent layer of Pliofllm and having a-terminal leading therefrom and a terminal leading from the metal cas- A stilLiurther object of the invention is to providea drycell batteryunit having the above ca'l' conducting member which-is disposed bedescribed. distinguishing features and characteristics and which issimple in construction and well adapted for quantity production at a minimum cost.

Another object of the invention is to provide a method of constructing, forming and assembling a dry cell battery unit having the hereinbefore mentioned distinguishing features and characteristics.

Another object of the invention is to provide a method of constructing a dry cell battery unit of the character described which can be carried out principally with automatic machinery and in which the number of manual operations are reduced to a minimum.

Further and more limited objects of the invention will appear as the description proceeds and by reference to the accompanying drawings in which Fig. 1 is a view in side elevation of an apparatus for constructing and assembling the dry cell battery unit herein described; Fig. 2 is a disassembled view disclosing the several parts which go to make up each cell; Fig. 3 is a vertical sectional view showing the apparatus for forming the cake of mix which forms a part oi.- each cell; Fig. 4 is a vertical sectional view taken on the line 4-4 of Fig. 1; Fig. 5 is a vertical sectional view of the completed dry cell battery unit; Fig. 6 is a horizontal sectional view on the line 6-6 of Fig. 5; and Fig. 7 is a greatly enlarged view of a portion of Fig. 5 to more clearly illustrate the construction of the cells and their relation relative to one another.

Referring now to the drawings, the reference character I designates a mold for forming the mix cake which is adapted to be supported upon a suitable support 2 which has an upstanding central portion 3 which fits within the recess provided in the mold. The mold l. has a centrally disposed bore 4 therein. In forming the cake of mix, a thin annular ring or strip 3"- of material such as fish paper or the like is firstplaced within the mold. Mix of the desired consistency, preferably of powdered form, and containing electrolyte is poured into the bore 4 to fill the same. Any additional mix is struck ofi.

A plunger 5 is then forced into the bore 4 to compress the powdered mix into cake form as shown most clearly in Fig. 2. The plunger has thereon a flange 6 and a downwardly depending portion 1. The plunger 5 is also provided with a downwardly extending tapered nose portion 8 which forms a depression in the top of the mix cake. The plunger is depressed until the flange 6 strikes against the shoulder .9 on the form'l with the result that a mix cake I is formed hav-. ing a central depression therein which is adapted to receive a carbon button l2. The mix cake, when removed from the. mold, will, of course, be enclosed within the'z'annular ring of fish paper which serves to strengthen the same and toprevent dehydration or a squeezing out of the electrolyte. The carbon button |2 has a circular recess |2 in .the top thereof and receives therein a spring-like electrical conductor l2 which serves to provide good electrical contact between the carbon button and the adjacent zinc electrode 33. It is 'of .course to be understood-that each mix cake is formed in a similar manner.

One form of apparatus for forming and assembling the cells within the battery will now be described.

The reference character |3 designates a base or supporting member to which is secured a press which comprises a bracket M to which is pivotally secured an arm |5. Carried by the arm I is a plunger l6 having ears thereon which enga in slots 8 provided in the arm I5. Carried by or formed integrally with the bracket 4 is a guid n member I3 having a central bore therein which receives therethrough the plunger I6. Also carried by the bracket I4 is a block 20 having an axially extending bo're 2| therein the lower end of which is slightly enlarged and adapted to receive therein an extruded zinc can or casing 22 in the position shown in Fig. 4. The block 20 is recessed at its upper end and has a peripheral shoulder 23 thereon. Fitting within the recess provided in the upper end of the block 20 is a guiding member 24 having a peripheral flange 25 thereon which rests on the shoulder 23. The guiding member 24 is of substantial thickness and has a centrally disposed bore or opening 26 therein. The guiding member 24 also has a depending portion 21 which fits within the recess in the block 20 and serves to position the same therein. The guiding member 24 is also provided on its upper side with an upstanding shoulder 28 which provides a recessed central portion 29. The guiding member is adapted to receive thereover the form or mold I, which contains the mix cake l0. As the mold I has the bottom thereof slightly recessed, a slight space is provided between the top surface of the guiding member 24 and the lower face of the mold Each cell comprises a thin layer or disk 30 of suitable insulating material, such as Pliofilm or the like, having a central opening 3| therein.

Pliofilm is hydrochlorinated rubber, that is, rubton I2 is a zinc disk or electrode 33. Disposed over the zinc electrode 33 is a layer or disk of bat tery paper 34 which is formed into a cup in a manner to' be hereinafter described and which receives the mix cake I0 therein. The carbon button is omitted from the lowermost layer of Pliofilm and the lowermost zinc electrode may, if desired,. be defiected downwardly through the opening in lowermost layer of Pliofilm as indicat ed at 33 so as to insuliegood electrical contact with the bottom of the shell 22. a

I The steps of forming the cells and assembling the battery unit will now be described: First, the outer casing 22 is inserted into the block 20 in the position shown in Fig. 4. A slide 35 secured to the support |3 by bolts 36 is then pulled outwardly to'the position shown in Fig. 1 to hold the container in place; then a layer or-disk 30, of Pliofilm or the like, without the carbon button secured thereto but having the central opening 3| therein, is disposed over the bore 2| in the block 20. The bore 2| is slightly larger than the though this disk may be placed over the opening layer dropped within the bore 26 so as to rest on. the

before the layer of Pliofllm is placed over the bore 2|. The disk of battery paper 34 is then placed over the opening 26in the member 24, the walls of the recessed central portion 29 serving to properly position the same. The mold with the mix cake therein is then placed over the member 24 in the position shown in Fig. 4. The plunger "3 is then depressed, which forces the mix cake and thepaper disk '34 downwardly against the Pliofilm disk and simultaneously folds the paper disk about the mix cake. As the plunger 16 is further depressed thebottom of the cup-shaped paper disk engages the zinc disk 34 and forces it together with the Pliofllm disk 30 downwardly. The walls of the bore 2| serve' to fold the Pliofilm disk about-the mix cake. The plunger is depressed sufliciently far to force the mix cake downwardly to a point slightly below the plane of the recessed upper end 'oithe block 20. The mold I and. the member 24 are then removed and a second 'Pliofllm disk is positioned over the bore 2|.

This disk oi Pliofllm has the carbon button l2 secured in the central opening SI and cemented thereto so that it will enter the depression II' in the previously inserted mix cake.

The member 24 is then again placed over this of Pliofilm and another zinc disk 33 is carbonbutton I2. A second diskof battery paper 34 is then placed within the recess 29. The mold I, or a similar mold with the mix cake therein, is

then placed over the member 24. The plunger I6 is again depressed which forcesthemix cake I0 and the battery paper 34 downwardly into the bore 28, thereby folding the paper disk about the mixcake. As the plunger is further depressed, the paper disk engages the adjacent lower layer of Pliofilm and moves it downwardly into the bore 2|. The carbon button l2 enters the central depression H in the mix cake. plunger is further depressed to a position'to force this mix cakedownwardly to a point slightly below the plane of the bottom of the member 24.

These operations are repeated in succession until the required number of cells have been formed and insertedinto the casing 22.

The'

" completed.

battery unit may then be trimmed ofi although that operation may be performed before the upper edge of the casing ing is then enclosed within an insulating jacket 39. A terminal 40 31 and a terminal 4| asphalt or the like is thenpoured over seal-42 is formed of asphalt or the like and is of is turned over. The metal casis then soldered or otherwise 'secured to the metal plate is secured to the metal. casing 22. A seal 42 of the top of the battery unit and seals both the metalcasing and the outer jacket. A second seal 43 prefersuch character that excessive pressure may be relieved therethroughwithout permitting-the inv gress of outside air.

It will be seen that each cell is progressively formed and projected into the outer casing successively and simultaneously with the forming operation thereof, and that each cell is also simultaneously enclosed within a thin layer of insulating material which is slightly distensibie and impervious to moisture and which hasliquid-tight engagement with each carbon electrode so as to prevent the escape of the liquid contents of the cell. The lowermost cell is disposed in electrical contact with the metal casing and the remaining cells are. insulated therefrom. The lower end of the metal casing 22 is provided at its bottom with an opening 44which permits the air to escape from the casing as the cells are projected therein. This opening is preferably closed by a drop of solder when the battery is The layers of Pliofllm have a thickness of ap very little space, thus permitting a maximum quantity of active materials to be used.

While I prefer to use Pliofllm, it is of course understood Itwill be noted that the diameter or size of" each Pliofllm disk is such that when it is folded upwardly about the next adjacent. mixcake, it

' extends to a point near the top of the next adjacent cell, or in other words, a Pliofllm layer overlaps each next adjacent cell for a substanthat I may make use of any thin insulating'material having the desired qualitiesandeharacteristics. It will be noted thateach cell is separately and individually encas'edwithin the layer of insulating material and that each layer vof insulating material has. the carbon electrode of the adjacent cell so as to of an inch and therefore occupy liquid-tight contact with.

- is secured in intimate electrical contact with the tial distance. As each layer of Pliofilm has a coating or film of oil applied thereto as it moves over the lowerface of the member 24, it adheres to the next adjacent layer of Pliofllm and tends to provide-a liquid-tight seal. The required number of cells are formed and inserted into the casing 22 until the casing isfilled to about the level shown in Fig. 5. Suiflcient pressure is applied to the cells through the plunger l8 so as. to insure intimate electrical contact between adjacent cells.

After the last cell is inserted in the casing-22, a thin metal disk 31 is placed over the last layer of Pliofllm in contact with the uppermost car- 'bon button l2. An insulating disk '38 is then placed over the metal disk 31 which has a central opening therein. The metal casing with the cells therein is then placed within a suitable fixture andthe cells placed under compression with considerable pressure. with the cells held in this condition, the upper edge of the metal casing is deflected over inwardly to hold the cellsin place in electrical contact with each other.- Any excess Plioiilmwhich may proiect from the top' .of the in. The particular sizeof the individual cells without departing from the spirit bottom of the metal casing and allof the other cells are thoroughly insulated from the metal casing; and all of the cells are maintained with i in the casing under considerable pressure, thereby insuring intimate electrical contact between the carbon electrode and the zinc electrode of adjacent cells. A dry cell of similar construction is disclosed in a copending application of Cyril ,P. Deibel and Lewis. A. Gray, Serial No. 407,014, filed August 15,1941.

. It is of course to be understood that the outer.

metal casing 'may be of any. desired size or shape sons to receive the desired number of .cells theremay also be varied as the exigencies of the occaskin may demand. Various other changes may be made in the shape. size and arrangement of parts as well-as inthe specific materials used and in the specific steps of the method employed of my invention. Y

It will now be clear that I have provided a dry cellbattcryunitandmethodofmakingthom ,casing a plurality of wafer-like dry cells arranged within said casing in stacked relation and connected in series, each cell comprising a zinc electrode, a cup-shaped member containing a mass of mix and an electrolyte and a carbon button embedded in said mass of mix and having a recessed upper surface, a spring-like electrical conductor arranged within said recess and engaging the next adiacent zinc electrode, a thin layer of insulating material surrounding each .cell and held in sealed relation with the next adjacent carbon button and preventing the escape of the liquid. contents of the cell.

2. A dry cell battery unit comprising a metal casing, a plurality of wafer-likedry cells arranged within said metal casing in stacked relation and connected in series, each cell comprising a zinc electrode, a cup-shaped member containing a mass of mix and an electrolyte and a carbon button embedded in said mass of mix and having a recessed upper surface, a spring-like electrical conductor arranged within said recess and engaging the next adjacent zinc electrode, a thin layer of insulating material surrounding each cell and held in sealed relationwith the next adjacent carbon button and preventig the escape or the liquid contents of the cell, each mass of mix being enclosed within a supporting ring.

' 3. A dry cell battery unit comprising an outer casing, a plurality of dry cells arranged within said casing, each cell comprising a zinc electrode, a mass of mix containing an electrolyte and a carbon electrode, a thin layer of insulating material surrounding each cell, each of said carbon electrodes being'partially embedded in the next adjacent mass of mix and having an exposed upper surface which is recessed, a spring-like conductor arranged within the recess in said carbon electrode and engaging the next adjacent zinc electrode, and a thin layer of sealingmaterial securing each of said layers of insulating material to the next adjacent carbon electrode in liquid-tight relation.

4. A dry cell battery unit comprising an outer I casing, a plurality of dry cells arranged within said casing, eachcell comprising a negative electrode, a mass of mix containing an electrolyte and a carbon electrode, a thin layer of insulating material surrounding each cell, each'oi said carbon electrodes being partially embedded in the next adjacent mass of mix and having snapper surface which is recessed, a spring-like conductor arranged within the recess in said carbon electrode and engaging the next adjacent negative electrode, a thin layer of sealing material secur- 65 mix being enclosed in a mg each of said layers of insulating material to having a recessed upper end, each cell being encased in a thin layer iii-insulating material having liquid-tight sealed engagement with the nextadjacent positive electrode, a spring-like conductor arranged within the recessed end of the positive to electrode and engagingthe next adjacent negative electrode, and means holding all of said cells within said outer casing under pressure and in intimate contact.

6. A dryrceli battery unit made up of an outer casing in which is arranged a plurality of waferlike dry cells in stacked relation, each cell comprising a negative electrode, a mass of mix containing a positive electrode embedded therein and having a recessed upper end, each cell being encased in a thin layer of insulating material having liquid-tight sealed engagement with the next adjacent positive electrode, a spring-like conductor arranged within the recessed end of the positive electrode and engaging the next adjacent negative electrode, and means holding all 01' said cells within said outer casing under pressure and in intimate contact, said thin layer of sealing material being tear resistant and impervious to moistureand gas and resistant to oil and hydrocarbons.

7. A dry cell battery unit made up of an outer casing in which is arranged a plurality of waferlike dry cells in stacked relation, each cell comprising a negative electrode, a mass of mix containing a positive electrode embedded therein and having a'recessed upper end, each cell being encased in a thin layer of insulating material having liquid-tight sealed engagement with the next adjacent positive electrode, a spring-like conductor arranged within the recessed end of the positive electrode and engaging the next adjacent negative electrode, and means holding all of said cells within said outer casing under pressure and in intimate contact, each mass of mix being encased in a supporting ring disposed within said insulating layer.

8. A dry cell battery unit comprising an outer casing, a plurality of dry cells arranged within said casing in stacked relation, each cell com-- prising a negative electrode, a mass of mix containing an electrolyte and a carbon electrode, a thin layer of insulating material surrounding each cell, each of said carbon electrodes being partially embedded in the next adjacent mass of mix, a spring-like electrical conductor carriedby each carbon electrode and engaging the next adjacent negative electrode, a thin layer of sealing material securing each of said layers of insulating material to the next adjacent carbon electrode in liquid-tight relation, each mass of reinforcing member.

CYRIL P. DEI'BEL.

3 Patent 3 2;507,765;"

CERTIFICATE (JP-CORRECTION.

January 12 -19145 CYRIL fD'EIB L;

, I It is hereby 'certified th'et error 'a p gi s 1h t he' pr inted epeoificetfon ofgtfieab ox e mqmberedpatent requiring cprr ectibh as fbllowez Bageh secend. eoiumn, lixie 11+, c l'a i m '5, after the word "pqsit1ve" strike out f't'o'"; and that the said Lettez s Patent shouldfpe re' aq with thi S QOI'TGGtiQIII 'thOIB in that the 'same may eonfegmto the: record'o'f the ycesein the Patent Office.

' signed ipd.seeled this lth day of nb ber, A-. 13. 1%}, a

' Henrjfvan Arsd'ale,

' 1 (Seei) Cqximissioner of Patents; 

